Starter system for portable internal combustion engine electric generators using a portable universal battery pack

ABSTRACT

A portable power driven system has a manually movable frame. In one example, an internal combustion engine and a generator device that generates AC power are supported on the frame. The internal combustion engine drives the generator device. An electrically powered starting device is coupled to the internal combustion engine. A control panel is coupled to the frame and includes at least one AC outlet and a battery receptacle that is electrically coupled to the starting device. The battery receptacle is materially the same as a foot of a cordless power tool that receives a battery pack. According to one aspect, the battery pack for the cordless power tool may be permanently mounted in the battery receptacle and provides electrical power to the starting device. The battery receptacle may be contained in an enclosure. The enclosure may provide biasing members urging the battery pack into the battery receptacle.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation-in-part of U.S. patentapplication Ser. No. 11/526,825 filed Sep. 25, 2006, which is acontinuation-in-part of U.S. patent application Ser. No. 11/321,773filed Dec. 29, 2005, now U.S. Pat. No. 7,309,928, which is acontinuation-in-part of U.S. patent application Ser. No. 10/453,988filed Jun. 4, 2003, now U.S. Pat. No. 7,180,200, which claims thebenefit of U.S. Provisional Application No. 60/386,904 filed Jun. 6,2002. U.S. Ser. No. 11/526,825 also claims the benefit of U.S.Provisional Application No. 60/727,201 filed Oct. 14, 2005 as does U.S.patent application Ser. No. 11/321,773.

The disclosures of the above applications are incorporated herein byreference.

FIELD OF THE INVENTION

This invention relates generally to electrical power generators. Moreparticularly, the invention relates to a system for utilizing aremovable, portable universal battery pack and a permanent magnetgenerator (PMG) to start an internal combustion (IC) engine of thegenerator.

BACKGROUND OF THE INVENTION

Present day portable generators typically make use of a starter motorand a fixed lead acid battery to start an internal combustion (IC)engine that drives an alternator, thereby producing an electrical poweroutput. The starter motor and fixed battery add size, bulk and weight tothe portable generator. As can be appreciated, since the generator isintended to be transportable, keeping the generator as light and assmall as possible is highly desirable.

In the latest portable generator technology, the alternator is replacedwith a smaller and lighter permanent magnet generator (PMG) and anelectronic power converter. In normal operation, the IC engine directlydrives the PMG which then produces electrical power. This variablefrequency (engine speed dependent), variable voltage power is thenconverted electronically to a constant voltage, constant frequencyoutput, for example a 120 VAC, 60 Hz output. Typically, a PMG includes asingle set of windings that are used to produce the electrical poweroutput of the portable generator.

It would be highly desirable to provide a portable generator thatutilizes a removable/portable universal battery pack adapted for usewith various other DC powered tools to start the generator, therebyeliminating the need for the fixed lead-acid battery and making thegenerator lighter in weight and more manageable to maneuver.

It would further be highly desirable to provide a portable generatorthat utilizes such a portable universal battery pack in combination witha PMG adapted to start the IC engine. This would eliminate the need forthe starter motor as well as the lead acid battery, thereby making thegenerator even lighter in weight and even more manageable to maneuver.

SUMMARY OF THE INVENTION

In accordance with an aspect of the invention, a portable power drivensystem has a manually movable frame. An internal combustion engine and agenerator device that generates AC power may be supported on the frame.The internal combustion engine drives the generator device. Anelectrically powered starting device is coupled to the internalcombustion engine. A control panel is coupled to the frame and includesat least one AC outlet and a battery receptacle that is electricallycoupled to the starting device. The battery receptacle is materially thesame as a foot of a cordless power tool that receives a battery pack.The battery pack for the cordless power tool may be permanently mountedin the battery receptacle and provides electrical power to the startingdevice.

In another aspect, a portable electrical generator has a manuallymovable frame. An internal combustion engine and a generator device thatgenerates AC power are supported on the frame. The internal combustionengine drives the generator device. An electrically powered startingdevice is coupled to the internal combustion engine. A control panel hasat least one AC outlet coupled to the generator device. An enclosure,supported by the frame, has a battery receptacle electrically coupled tothe starting device. The battery receptacle is configured to receive abattery pack from a cordless power tool. A charging circuit may beelectrically coupled between the battery receptacle and the generatordevice and selectively adapted to charge the battery pack duringoperation of the power generating device.

According to additional features, the enclosure may include a hinged lidportion movable between an open position and a closed position. The lidportion may have at least one biasing member adapted to urge the batterypack into the battery receptacle in a closed position.

According to another aspect, the battery receptacle of the generatorsystem may define a first configuration. An adapter may define aninsertion portion. The insertion portion may be selectively receivedinto the battery receptacle. The adapter may include a receiving portionhaving a second configuration adapted to receive a second battery packfrom a second cordless power tool. The second configuration may bedistinct from the first configuration.

In an aspect, the battery receptacle receives a battery pack that is oneof a plurality of battery packs having different voltages and thegenerator includes a voltage regulation circuit that couples the batteryreceptacle to the starting device. The voltage regulation circuitprovides at an output coupled to the starting device a voltage at adesired level for the starting device regardless of the voltage of thebattery pack received in the battery receptacle.

In other aspects, the portable power driven system may include an aircompressor and a power washer.

According to additional features, a portable electric generator has acontrol panel assembly comprising a control panel, a housing and acharger assembly, which includes a charger. The charger assemblyincludes a base portion and a cage portion, which are mated tosubstantially enclose the charger. The charger may be directly connectedto the output of the generator or may include a wire plug for plugginginto an AC outlet of the electric generator.

Further areas of applicability of the present invention will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating the preferred embodiment of the invention, are intended forpurposes of illustration only and are not intended to limit the scope ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description and the accompanying drawings, wherein:

FIG. 1 is a simplified block diagram of a portable generator system, inaccordance with an embodiment of the present invention, wherein thesystem utilizes a portable universal battery pack to start an internalcombustion (IC) engine of the generator system;

FIG. 2 is a simplified block diagram of an alternate embodiment of theportable generator system shown in FIG. 1;

FIG. 3 is a simplified block diagram of another alternate embodiment ofthe portable generator system shown in FIG. 1 that utilizes a permanentmagnet generator and electric converter to generate power;

FIG. 4 is a simplified block diagram of yet another alternate embodimentof the portable generator system shown in FIG. 1 that utilizes apermanent magnet generator to start the IC engine;

FIG. 5 is a simplified block diagram of still yet another alternateembodiment of the portable generator system shown in FIG. 1, thatutilize the permanent magnet generator to start the IC engine;

FIG. 6 is a simplified schematic drawing of an embodiment of a brushlessDC drive circuit used in the portable generator system shown in FIG. 5;

FIG. 7 is a simplified schematic drawing of another embodiment of abrushless DC drive circuit used in the portable generator system shownin FIG. 4;

FIG. 8 is a side perspective view of a portable generator in accordancewith an aspect of the invention;

FIG. 9 is a front view of a control panel of the portable generator ofFIG. 8;

FIG. 10 is a front perspective view of the control panel of FIG. 9;

FIG. 11 is a side perspective view of a battery pack;

FIG. 12 is an exploded perspective view of a battery receptacle of thecontrol panel of FIG. 9;

FIG. 13 is an exploded perspective view of the battery receptacle of thecontrol panel of FIG. 9;

FIG. 14 is a side perspective view of a portable generator in accordancewith an aspect of the invention;

FIG. 15 is a side perspective view of housing halves of a cordlessdrill;

FIG. 16 is a schematic showing a voltage regulation circuit coupling thebattery receptacle of the portable generator of FIG. 8 to the startingdevice of the portable generator of FIG. 8;

FIG. 17 is a simplified block diagram of a portable generator system, inaccordance with another alternate embodiment of the present invention,wherein the system utilizes a permanently mounted universal battery packto start an internal combustion engine of the generator system;

FIG. 18 is a simplified block diagram of a portable generator system, inaccordance with another alternate embodiment of the present invention,wherein the system utilizes an actuator switch for connecting a portableuniversal battery pack to either a starting device to start an internalcombustion engine of the generator system or to a charging circuit forcharging the portable universal battery pack;

FIG. 19 is a side perspective view of the portable generator of FIG. 14shown with biasing elements in a lid of a battery pack/charger enclosureaccording to another embodiment;

FIG. 20 is a sectional view taken along line 20-20 of FIG. 19;

FIGS. 21 and 22 are side perspective views of adapters for acceptingbattery packs having various geometries;

FIG. 23 is a side perspective view of a compressor in accordance with anaspect of the invention;

FIG. 24 is a side perspective view of a power washer in accordance withan aspect of the invention;

FIG. 25 is a side perspective view of a control panel assembly inaccordance with an aspect of the invention;

FIG. 26 is a top perspective view of a housing of a control panelassembly in accordance with an aspect of the invention;

FIG. 27 is a side perspective view of a charger assembly in accordancewith an aspect of the invention;

FIG. 28 is a side perspective view of a base portion of a chargerassembly in accordance with an aspect of the invention;

FIG. 29 is a diagram of a side view of a portion of the battery pack andthe battery pack charger showing one example of the indicating mechanismincluding a contact member extending from the battery pack charger andcontacting the battery pack in accordance with the present teachings;

FIG. 30 is similar to FIG. 29 and shows another example of theindicating mechanism including a contact member extending from thebattery pack and contacting the battery pack charger in accordance withthe present teachings;

FIG. 31 is a diagram of a side view of a portion of the battery pack andthe battery pack charger showing a further example of the indicatingmechanism providing an electromagnetic wave signal in accordance withthe present teachings;

FIG. 32 is a simplified perspective view of an exemplary battery packhaving the tower configuration and showing an exemplary location of theindicating mechanism in accordance with the present teachings;

FIG. 33 is a simplified top view of an exemplary battery pack showinganother location of the indicating mechanism in accordance with thepresent teachings;

FIG. 34 is a simplified bottom view of an exemplary battery pack showinga different location of the indicating mechanism in accordance with thepresent teachings;

FIG. 35 is a simplified side view of an exemplary battery pack showinganother location of the indicating member in accordance with the presentteachings;

FIG. 36 is a simplified side view of an exemplary battery pack showing afurther location of the indicating member in accordance with the presentteachings;

FIG. 37 is a simplified front view of an exemplary battery pack showingyet another location of the indicating member in accordance with thepresent teachings;

FIG. 38 is a simplified rear view of an exemplary battery pack showing adifferent location of the indicating member in accordance with thepresent teachings;

FIG. 39 is a simplified perspective view of an exemplary battery packhaving an alternative tower configuration such that the battery pack isconfigured with an enlarged tower portion and showing a further locationof the indicating mechanism in accordance with the present teachings;

FIG. 40 is a perspective view of a battery receptacle;

FIG. 41 is a cross-sectional view of the battery receptacle of FIG. 40;

FIG. 42 is a perspective view of the terminal slot part of the batteryreceptacle of FIG. 40;

FIG. 43 is a perspective view of the battery receptacle of FIG. 40affixed to a mounting plate and a terminal board;

FIG. 44 is a top plan view of a portion of the terminal board of FIG.43;

FIG. 45 is a cross-sectional view of the battery receptacle of FIG. 40with an exemplary battery pack being partially inserted therein;

FIG. 46 is a cross-sectional view of the battery receptacle of FIG. 40with an exemplary battery pack completely inserted therein; and

FIG. 47 is a cross-sectional view of the battery receptacle of FIG. 40with an exemplary magnetic sensor and an exemplary battery packcompletely inserted therein.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiment(s) is merelyexemplary in nature and is in no way intended to limit the invention,its application or uses.

FIG. 1 is a simplified block diagram of a portable generator system 10,in accordance with an embodiment of the present invention. The generatorsystem 10 utilizes a portable universal battery pack 12 to start aninternal combustion (IC) engine 14 that turns a power generating device16. System 10 additionally includes a starting device 18 connected touniversal battery pack 12 and a starter switch 20. Starter switch 20 isconnected to a transistorized ignition unit 24, which is in turnconnected to a spark plug 26. Starting device 18 is used to turn ICengine 14 at a rate sufficient to start IC engine 14. Once IC engine 14is started, IC engine 14 drives power generating device 16, wherebypower generating device 16 outputs AC power usable by a load connectedto an electrical outlet 22.

FIG. 2 is a simplified block diagram of a portable generator system 30,which is an alternate embodiment of portable generator system 10 (shownin FIG. 1). In this embodiment, starting device 18 comprises a startermotor 32 and a starter solenoid 34. Additionally, power generatingdevice 16 is an alternator 36. System 30 utilizes portable universalbattery pack 12 to start IC engine 14 that turns alternator 36. Startersolenoid 34 is connected to battery pack 12 and used to initially turnstarter motor 32. Starter solenoid 34 is also connected to starterswitch 20. Starter switch 20 has a ‘Start’ position, an ‘On’ positionand an ‘Off’ position. When starter switch 20 is placed in the ‘Start’position, universal battery pack 12 provides low current power tostarter solenoid 34.

Providing low current to starter solenoid 34 turns on starter motor 32,thereby turning IC engine 14. Starter switch 20 is spring-loaded so thatit returns to the ‘ON’ position upon successfully starting IC engine 14.In the ‘ON’ position starter switch 20 directs power from ignition unit24 to spark plug 26. Each time spark plug 26 fires, spark is provided toIC engine 14, which is utilized to ignite a compressed fuel and airmixture present in a cylinder (not shown) during a compression cycle ofIC engine 14. When IC engine 14 is running it turns alternator 36, whichcreates an output voltage usable to provide AC power at outlet 22.

FIG. 3 is a simplified block diagram of a portable generator system 50,which is an alternate embodiment of portable generator system 30 (shownin FIG. 1). In this embodiment, starting device 18 again comprisesstarter motor 32 and starter solenoid 34, while power generating device16 comprises a permanent magnet generator (PMG) 52 and an electronicconverter circuit 54. Generator system 50 utilizes portable universalbattery pack 12 to start IC engine 14 that turns PMG 52, which isconnected to electronic converter circuit 54. As described above inreference to FIG. 2, starter switch 20 has a ‘Start’ position, an ‘On’position and an ‘Off’ position. When starter switch 20 is placed in the‘START’ position, universal battery pack 12 provides low current powerto starter solenoid 34 to start IC engine 14 as described above.

When IC engine 14 is running it turns PMG 52, which creates a 3-phaseoutput. The 3-phase output is converted by the electronic convertercircuit 54 to usable AC power that is provided to outlet 22. Theelectronic converter circuit 54 can be any suitable inverter circuit,such as the inverter circuit described in patent application Ser. No.10/077,219, filed Feb. 15, 2002, entitled Alternator/Inverter With DualH-Bridge, herein incorporated by reference in its entirety.

FIG. 4 is a simplified block diagram of a portable generator system 70,which is yet another alternate embodiment of portable generator system10 (shown in FIG. 1). In this embodiment, power generating device 16again comprises PMG 52 and electronic converter circuit 54.Additionally, starting device 18 also comprises PMG 52. PMG 52 includestwo sets of 3-phase windings, referred to herein as first windings 52 aand second windings 52 b. First and second windings 52 a and 52 b enablePMG 52 to be used as a starter motor for starting IC engine 14, i.e.‘Motor Mode’, and a generator for generating AC power output to outlet22, i.e. ‘Generator Mode’. One set of first and second windings 52 a, 52b is used to drive PMG 52 as an electric motor when PMG 52 is in the‘Motor Mode’ and the other set of first and second windings 52 a, 52 bis used to generate power when PMG 52 is in the ‘Generator Mode.’

Generator system 70 utilizes PMG 52 to start IC engine 14 and togenerate AC power. Universal battery pack 12 is connected to PMG 52 viaa brushless DC (BLDC) controller 72 and the starter switch 20. When PMG52 is used in the ‘Starter Mode’, starter switch 20 is placed in the‘Start’ position. Battery pack 12 then provides power to PMG 52, viaBLDC controller 72, to drive PMG 52 as a brushless DC motor so that PMG52 turns IC engine 14. As IC engine 14 turns, ignition unit 24 firesspark plug 26 at predetermined intervals. Each time spark plug 26 fires,spark is provided to IC engine 14. The spark is utilized to ignite thecompressed fuel and air mixture present in the cylinder during thecompression cycle of IC engine 14. Once the IC engine 14 is started,starter switch 20 is placed back to the ‘On’ position and IC engine 14continues running. PMG 52 then stops functioning as a starter motor andswitches to the ‘Generator Mode’. Thus, PMG 52 begins to function as agenerator. As described above in reference to FIG. 3 PMG 52 creates a3-phase output that is converted by the electronic converter circuit 54to usable AC power that is provided to outlet 22.

FIG. 5 is a simplified block diagram of a portable generator system 90,which is still yet another alternate embodiment of portable generatorsystem 10 (shown in FIG. 1). As in system 70, shown in FIG. 4, PMG 52 isused in the ‘Motor Mode’ to start IC engine 14 and used in the‘Generator Mode’ to provide power to outlet 22. However, in thisembodiment, the variable voltage, variable frequency power output by PMG52 is converted to usable AC power, i.e., constant voltage, constantfrequency AC power, utilizing BLDC controller 73.

Generator system 90 utilizes PMG 52 to start IC engine 14 and togenerate AC power. As described above in reference to FIG. 4, universalbattery pack 12 provides power to PMG 52, via BLDC controller 73, suchthat PMG 52 starts IC engine 14. Once the IC engine 14 is started,starter switch 20 is placed back to the ‘On’ position and IC engine 14continues running. PMG 52 then stops functioning as a starter motor andswitches to the ‘Generator Mode’ to provide power to outlet 22. Morespecifically, PMG 52 creates a 3-phase output. The 3-phase output isconverted to AC power by a controlled full wave bridge rectifier circuitand H-bridge bridge circuit included in BLDC controller 73.

FIG. 6 is an embodiment of a brushless DC drive circuit 100 included inBLDC controller 73 (FIG. 5). Circuit 100 is ideally suited for use in aportable electric power generator, however, it will be appreciated thatthe invention is not so limited and may find utility in a variety ofrelated power generating applications.

Circuit 100 is electrically connected to PMG 52 (shown in FIG. 5) whichis a three phase permanent magnet generator having first 3-phasewindings 52 a for running PMG 52 in the ‘Generator Mode’ and second3-phase windings 52 b for running PMG 52 in the ‘Motor Mode’. In‘Generator Mode’, PMG 52 outputs electrical power, such as to a load108, while in ‘Motor Mode’ PMG 52 rotates IC engine 14 (shown in FIG.5).

In ‘Generator Mode’, PMG 52 provides a three phase AC output signal to acontrolled full wave bridge rectifier circuit 122. Rectifier circuit 122is coupled across DC bus lines, or rails, 128 and 134 that form a DCbus. Also coupled across the DC bus is a full H-bridge circuit 140comprising four identical power switching devices 146 a-146 d. Aninductor 152 and a capacitor 158 are coupled across nodes 164 and 170and form an LC filter for attenuating harmonic distortion in the outputwaveform generated by the H-bridge 140. Each of the power switchingdevices 146 a-146 d may comprise a variety of suitable power switchingcomponents, for example field effect transistors (FET's) or insulatedgate bi-polar transistors (IGBT's). A pair of DC bus capacitors 176 and182 are also coupled in series across the DC bus rails 128 and 134.Although the DC bus capacitance is shown to only include the pair ofcapacitors 176 and 182, it is envisioned that the DC bus capacitancecould comprise any even number of capacitors. One phase of secondwindings 52 b is connected at a center node between even numbers of theDC bus capacitors.

Load 108 is coupled in parallel across capacitor 158. Additionally, DCdrive circuit 100 includes a 4-pole relay switch 194 that includes fourpoles 200 a-200 d and a coil 218. Universal battery pack 12 is removablyinserted in series with key switches 206 and 212 between DC bus lines128 and 134.

In starting operation, with 4-pole, double throw switch 194de-energized, as shown, load 108 is disconnected and the three phases ofsecond windings 52 b are connected to center nodes 164 and 170 ofH-bridge 140 and a center node 224 of the DC bus capacitance. With keyswitches 206 and 212 turned to a ‘Start’ position, portable universalbattery pack 12 is connected across DC bus rails 128 and 134 and powerswitching devices 146 a-146 d are sequenced to run PMG 52 in the ‘MotorMode’. In this mode PMG 52 acts as a motor to turn IC engine 14. Thepower switching devices 146 a-146 d are sequenced by signals from a Halleffect position sensor (not shown) and coupled, via an AND gate (notshown), with a pulse width modulated (PWM) signal. Power switchingdevices 146 a-146 d create two phases of a three phase drive signal usedto drive PMG 52 as a brushless DC motor with capacitors 176, 182creating the third phase.

The PWM signal is based on the rated voltage output of universal batterypack 12. Thus, the rated voltage output of universal battery pack 12need not conform to one predetermined DC voltage. The rated voltageoutput of universal battery pack 12 can be, for example, a voltagepreferably of 12 volts or greater, preferably ranging from 12 to 18volts. For example, a NiCd universal battery pack of 12, 14.4 or 18volts can be utilized with circuit 100 and regardless of the outputvoltage, the effective voltage provided to PMG second windings 52 b willbe approximately equal to that of a 12 volt battery.

When the DC bus voltage exceeds the initial voltage of universal batterypack 12, for example 20 volts or greater, relay coil 218 is energized todisconnect second windings 52 b from H-bridge circuit 140 and buscapacitors 176 and 182 and to connect load 108 to the output of H-bridgecircuit 140. Once second windings 52 b are disconnected from H-bridgecircuit 140, PMG 52 is switched to ‘Generator Mode’. In ‘GeneratorMode’, PMG 52 outputs variable voltage, variable frequency AC power, viafirst windings 52 a. Full wave bridge rectifier circuit 122 and H-bridgecircuit 140 convert the AC power to a constant voltage, constantfrequency output, for example a 120 VAC, 60 Hz, that is output fromH-bridge circuit 140 to load 108.

Utilizing universal battery pack 12 and PMG 52 to provide starting powerto IC engine 14 greatly reduces the size and weight of generator system90. It is envisioned that universal battery pack 12 can be any universalbattery pack commonly used in many cordless power tools, for example theDEWALT XR PLUS (Extended Run Time Plus) line of batteries.

FIG. 7 is a simplified schematic drawing of a preferred embodiment of abrushless DC motor drive circuit 250 included in BLDC controller 72 usedin portable generator system 70 (shown in FIG. 4). Drive circuit 250 isused to drive PMG 52 as a brushless DC motor to start IC engine 14(shown in FIG. 4). Circuit 250 is a low voltage DC to AC 3-phaseinverter that incorporates a Brushless DC/Permanent Magnet Generator(BLDC/PMG) starter control 256, and is powered directly by universalbattery pack 12. DC drive circuit 250 includes a power stage 262 that iselectrically connectable to PMG 52 through a 3-pole relay switch 268.Power stage 262 includes six identical power switching devices 274 a-274f coupled across DC bus lines, or rails, 280 and 286.

Power switching devices 274 a and 274 b are connected in series betweenbus lines 280 and 286 having a center node 298 electrically connected toone pole of relay 268. Power switching devices 274 c and 274 d areconnected in series between bus lines 280 and 286 having a center node304 electrically connected to a second pole of relay 268. Powerswitching devices 274 e and 274 f are similarly connected in seriesbetween bus lines 280 and 286 having a center node 310 electricallyconnected to a third pole of relay 268. Six diodes 292 a-292 f arerespectively connected in parallel with switching devices 274 a-274 f,between bus lines 280 and 286. Switching devices 274 a-274 f maycomprise a variety of suitable power switching components, for examplefield effect transistors (FET's), insulated gate bi-polar transistors(IGBT's), or metal oxide silicon field effect transistors (MOSFET's).

The 3-phase PMG 52 includes position sensors 320, 322 and 324, which areillustratively Hall effect sensors, that are connected to BLDC/PMGstarter control 256 by lines 314, 316 and 318, respectively. Positionsensors 320, 322, 324 sense the position of a rotor (not shown) of PMG52. Additionally, DC drive circuit 250 includes a momentary starterswitch 330 that controls the flow of current from universal battery pack12 to BLDC/PMG starter control 256.

In operation, initially IC engine 14 is at rest. The IC engine 14 isstarted by a user closing momentary start switch 330. The BLDC/PMGstarter control 256 will then become energized by universal battery pack12. Provided the position sensors 320, 322 and 324 indicate that eitherthe speed of IC engine 14 or the speed of PMG 52 is less than apredetermined value, e.g. 600 rpm, 3-pole relay switch 268 will beenergized by BLDC/PMG starter control 256, thereby connecting the3-phase power stage 262 to PMG 52. Utilizing information from positionsensors 320, 322 and 324, the switching devices 274 a-274 f are turnedon and off by BLDC/PMG starter control 256. The switching of switchingdevices 274 a-274 f electronically commutates second 3-phase windings 52b within PMG 52 to drive PMG 52 as a brushless DC motor to rotate ICengine 14 to start it.

Thus, when PMG 52 is in ‘Motor Mode’, IC engine 14 will be turned by PMG52 acting as a motor and will accelerate up to a speed to start ICengine 14. Once IC engine 14 has started, PMG 52 is driven past apredetermined maximum speed, e.g. 600 rpm, and 3-pole relay switch 268will then be de-energized, thereby disconnecting power stage 262 fromPMG 52. Disconnecting power stage 262 avoids overdriving universalbattery pack 12 and supplying excessive voltage to switching devices 274a-274 f. Once the starting operation is complete, momentary starterswitch 330 is opened.

BLDC/PMG starter control 256 can be microprocessor based to simplify theelectronic circuitry and to provide additional control features.Additional control features may include setting a maximum cranking time,e.g. 5 seconds, to avoid damage if momentary starter switch 330 is heldclosed for too long, or not attempting starting of IC engine 14 whenuniversal battery pack 12 does not have sufficient voltage to turn orstart IC engine 14. Further control features provided by amicroprocessor based BLDC/PMG starter control 256 may include speeddetection and control of 3-pole relay switch 268 to avoid overdrivinguniversal battery pack 12 and power stage 262. Even further controlfeatures may include setting an upper starting speed of PMG 52regardless of the voltage of universal battery pack 12 by utilizingpulse width modulation control of switching devices 274 a-274 f above aminimum speed.

In an alternate embodiment, PMG 52 includes a single set of tappedwindings. In this embodiment, the first windings 52 a comprise the fullwindings, which are used to generate AC power in the ‘Generator Mode’.The second windings 52 b comprise the tapped portion of the windings,which are used to drive PMG 52 as a motor in the ‘Motor Mode’ to startthe IC engine 14.

Although the present invention has been shown and described inconnection with a portable generator using a single PMG and a singlealternator/inverter circuit, or a single brushless DC drive circuit, thepresent invention could just as readily be adapted for use with startersystems of portable generators utilizing a pair of PMG's and a pair ofalternator/inverter circuits. Alternatively, the present invention couldbe used with a portable generator using a pair of PMG's with a pair ofbrushless DC motor drive circuits, such as that described in patentapplication Ser. No. 10/077,386, filed Feb. 15, 2002, entitledAlternator/Inverter With Dual H-Bridge and Automatic Voltage Regulation,herein incorporated by reference in its entirety. The invention isfurther applicable to all types of small IC engines, for example alawnmower engine. Thus, the scope of the invention should not beconstrued as being limited only to portable generators.

The present invention thus provides a means for starting an internalcombustion engine utilizing a universal battery pack, wherein theuniversal batter pack is able to be used with other cordless powertools. Also, by controlling an H-Bridge switching circuit in apredetermined switching sequence, the H-Bridge can be used to controlthe application of power to a PMG to enable the PMG to be effectivelyused as a starter motor to start the internal combustion engine.

FIG. 8 shows a portable generator 800 in accordance with an aspect ofthe invention. As used herein, a portable generator has an electricgenerator device for generating AC power that is driven by an internalcombustion engine and is sufficiently light that it can be manuallymoved from one place to another. Portable generator 800 includes a frame802 that supports an internal combustion engine 804. Frame 802 mayillustratively support wheels 805 (only one of which is shown in FIG. 8)and include handles 807 to facilitate manually moving portable generator800. An electric generator device (hidden from view in FIG. 8) iscoupled to an output shaft of internal combustion engine 804. Theelectric generator device generates AC power, such as has been describedabove. The AC power may illustratively be 120 VAC (or 110 or 115 VAC)and may also illustratively be 240 VAC (or 220 or 230 VAC). It may be 60Hz, or may be 50 Hz.

Portable generator 800 further includes a control panel 806, shown inmore detail in FIGS. 9 and 10. Referring to FIGS. 9 and 10, controlpanel 806 includes AC outlets 900. AC outlets 900 illustratively includeground fault interrupter outlets 902 and twist-lock outlets 904. Controlpanel 806 also includes on/off/start switch 906, circuit breakers 908,and idle speed control switch 910. Control panel 806 further includesbattery receptacle 912 electrically coupled to an electrically poweredstarting device for starting internal combustion engine 804, such as thestarting devices described above.

Battery receptacle 912 may illustratively be a “foot” of a cordlesspower tool that receives a battery pack, such as battery pack 1100 (FIG.11). As used herein, a “foot” of a cordless power tool is that portionof the power tool, typically part of the power tool's housing, that isconfigured to receive a battery pack. For example, battery pack 1100 maybe a battery pack for the DEWALT series of 18 volt cordless power toolsand battery receptacle 912 would then illustratively be materially thesame as the foot of these power tools, such as the DEWALT DW959K-2drill. FIG. 15 shows housing halves 1500 of the DEWALT DW959K-2 drill,the lower portions of which comprise the foot of this cordless powertool. It should be understood, however, that battery receptacle 912could be the foot of any cordless power tool that uses a removablebattery pack.

With reference to FIGS. 9-12, battery receptacle 912 illustrativelyincludes housing halves 914 mated together to form a housing 915. Acollar 917, illustratively a rectangular shaped collar, surroundshousing 915 and includes screw posts 1200 (only one of which is shown inFIG. 12) for receiving screws which secure collar 917 to control panel806. Housing 915 includes a base portion 919 having an outer plate 916that conforms to an upper plate 1102 of battery pack 1100 (FIG. 11) anda columnar portion 1218 (FIG. 12) extending from base portion 919.Opposed flanges 1214 (FIG. 12) project outwardly from housing halves 914at opposed edges of outer plate 916. Opposed flanges 1214 include slots1216 therein that mate with inwardly extending projections 1300 (FIG.13) of collar 917 to secure housing 915 to control panel 806 when collar917 is secured to control panel 806.

Housing 915 has a bore or passageway 918 therein that conforms to atower 1104 of battery pack 1100 that extends from a base 1101 of batterypack 1100. Battery receptacle 912 further includes opposed catches 920at opposed sides of outer plate 916 which mate with latches 1106 (onlyone of which is shown in FIG. 11) of battery pack 1100. Catches 920illustratively include slots 922 that receive projections 1108 oflatches 1106 of battery pack 1100. It should be appreciated that latches1106 of battery pack 1100 are spring latches in which buttons 1110 oflatches 1106 are depressed to retract projections 1108 from slots 922 ofcatches 920. Housing 915 of battery receptacle 912 further includes akeyway 924 in outer plate 916 projecting from bore 918 that receives akey 1124 at the base of tower 1104 of battery pack 1100.

Battery receptacle 912 further includes a connector 1202 (FIG. 12) thatmates with terminal block 1112 of battery pack 1100. Connector 1202 iselectrically coupled to a starting device for internal combustion engine804 in a manner similar to that described above. Terminal block 1112 ofbattery pack 1100 includes power terminals 1114, 1116, temperature senseterminal 1118 (which is connected to a temperature sensing elementwithin battery pack 1100 such as a thermistor) and key 1120 surroundedby a rectangular wall 1122 having a key 1124 projecting outwardly froman end wall. Connector 1202 has corresponding power terminals 1204,1206. Terminals 1204, 1206 are spaced from each other and have a space1208 therebetween which receives temperature sense terminal 1118 and key1120. Terminals 1204, 1206 are surrounded by a rectangular wall 1212. Itshould be understood that connector 1202 could have a female temperaturesense terminal (not shown) if generator 800 includes circuitry to sensethe temperature of battery pack 1100.

Housing halves 914 include opposed channels 1210 that receive opposedflanges of connector 1202 to mount connector 1202 in housing 915.

By providing on control panel 806 a battery receptacle 912 that isessentially a foot of a cordless power tool, a user of generator 800 canadvantageously use the battery pack for the cordless power tool, such asbattery pack 1100, in starting generator 800. Illustratively, batterypack 1100 is not charged by generator 800. Rather, when battery pack1100 needs charging, it is charged in an external charger, such as theexternal charger that is typically provided with the cordless power toolwhen the user purchases the cordless power tool.

By using a battery pack from a cordless power tool, such as battery pack1100, generator 800 does not require its own battery, which is typicallya lead acid type of battery. The user need not purchase the lead acidbattery, avoids the need to maintain such a lead acid battery, andgenerator 800 is lighter since the weight of the lead acid battery iseliminated.

FIG. 14 shows another aspect of the invention. In the embodiment of FIG.14, a portable electric generator 1400 includes a frame 1402 thatsupports an internal combustion engine 1404. Frame 1402 mayillustratively support wheels 1401 (only one of which is shown in FIG.8) and include handles 1403 for facilitating moving generator 1400. Anelectric generator device (hidden from view in FIG. 14) is coupled to anoutput shaft of internal combustion engine 1404. The electric generatordevice generates AC power, such as has been described above. The ACpower may illustratively be 120 VAC (or 110 or 115 VAC) and may alsoillustratively be 240 VAC (or 220 or 230 VAC). It may be 60 Hz, or maybe 50 Hz. Generator 1400 also includes a control panel including ACoutlets (not shown in FIG. 14).

Generator 1400 further includes enclosure 1406 mounted to frame 1402.Enclosure 1406, which may illustratively be a water resistant enclosure,includes a rectangular tub shaped base portion 1408 and hinged lid 1410.Base portion 1408 of enclosure 1406 includes battery receptacle 1412,charger 1414 and AC outlet 1416. Battery receptacle 1412 is configuredto receive a battery pack from a cordless power tool, such as batterypack 1100. In this regard, battery receptacle 1412 may be configured toreceive a tower type of battery pack, such as battery pack 1100, as ischarger 1414. As such, battery receptacle 1412 may illustratively have aconfiguration similar to battery receptacle 912 described above. Batteryreceptacle 1412 may alternatively be configured to receive a rail typeof battery pack, such as battery pack 16 shown in U.S. Pat. No.6,653,815, the disclosure of which is incorporated herein in itsentirety by reference. As such, battery receptacle 1412 has aconfiguration similar to that on the foot of tool 10 of U.S. Pat. No.6,653,815. That is, battery receptacle 1412 includes a pair of groovesthat receives guide rails of the rail type battery pack. It alsoincludes a connector configured to mate with the terminal block of therail type battery pack.

Charger 1414 may illustratively be a stand alone charger such as thecharger that is typically supplied with the power tool when the userpurchases the power tool and is thus mounted in base portion 1408 ofenclosure 1406 and plugged into AC outlet 1416 in enclosure 1406.Charger 1414 may illustratively be a multi-port charger having aplurality of ports to that charger 1414 can receive a plurality ofbattery packs 1100 at any one time to charge them simultaneously.Battery receptacle 1412 is electrically coupled to an electricallypowered starting device for starting internal combustion 1404, such asthe starting devices described above.

In use, a battery pack, such as battery pack 1100, from a cordless powertool is placed in battery receptacle 1412 and provides electrical powerto start internal combustion engine 1404. Charger 1414 is used to chargeone or more battery packs 1100. In this regard, once internal combustionengine 1404 is started, the battery pack 1100 in battery receptacle 1412can be removed from battery receptacle 1412 and placed in charger 1414to charge that battery pack 1100.

Internal combustion engine 1404 may have a pull start that can be usedto start internal combustion engine 1404 as well as the electricalstarter circuit described above. The pull start could then be used tostart internal combustion engine 1404 when the battery pack 1100 isdischarged. Battery pack 1100 can then be placed in charger 1414,charged, and then placed in battery receptacle 1412 to provideelectrical power to the electrical starting device so that internalcombustion engine can be electrically started.

In an aspect of the invention, portable generator 800 is adapted to useuniversal battery packs having different voltages. More specificallywith reference to FIG. 16, portable generator 800 includes a voltageregulation circuit 1600 that couples connector 1202 of batteryreceptacle 912 to the starting device for internal combustion engine804, thus coupling the output of battery pack 1100 to the startingdevice for internal combustion engine 804 when battery pack 1100 isreceived in battery receptacle 912. Voltage regulation circuit 1600illustratively provides at its output 1602 a set voltage at theappropriate level for the starting device for internal combustion engine804. For example, if the starting device for internal combustion engine804 utilizes a 12 volt DC starter motor, then voltage regulation circuit1600 provides 12 volts DC at its output 1602. Voltage regulation circuit1600 may illustratively monitor the voltage at its output 1602 andadjust its output accordingly to maintain the appropriate voltage level.

Voltage regulation circuit 1600 may be any known type of voltageregulation circuit. It may, for example, be a DC-DC converter in whichthe switching device(s) in the DC-DC converter are switched with a pulsewidth modulated signal and the duty cycle of the pulse width modulatedsignal is controlled to obtain the desired voltage level at output 1602.That is, voltage regulation circuit 1600 compares the voltage at itsoutput 1602 with the desired voltage and adjusts the duty cycle of thePWM signal to maintain the output voltage constant at the desired level.

Voltage regulation circuit 1600 may illustratively be a buck convertertype of DC-DC converter. Since buck converters are step-down converters,the starter motor used would then illustratively be a low voltagestarter motor such that the voltage of the starter motor is no greaterthan the lowest voltage universal battery pack utilized. Alternatively,voltage regulation circuit 1600 may illustratively be a boost convertertype of DC-DC converter. Since boost converters are step-up converters,the starter motor used would then illustratively be a higher voltagestarter motor such that the voltage of the starter motor is no lowerthan the highest voltage universal battery pack utilized. Voltageregulation circuit 1600 may also illustratively be a buck-boost type ofDC-DC converter which can both step-up and step-down. The starter motorutilized can then have a voltage that falls between the voltage of thehighest voltage universal battery pack utilized and the voltage of thelowest voltage universal battery pack utilized. It should be understoodthat generator 1400 can similarly have voltage regulation circuit 1600.

With reference now to FIG. 17, a simplified block diagram of a portablegenerator system 1610, according to additional features is shown. Thegenerator system 1610 utilizes a battery pack 1612 that is mounted togenerator system 1610 with fastening devices, such as one or more holddown members shown representatively by 1617. Hold down member(s) 1617may be removably affixed to housing 1616 such as with screws (notshown). Battery pack 1612 is thus “permanently mounted” in housing 1616in the sense that it is not easily removable by hand. But battery pack1612 can be removed and replaced in the event of failure, such as byunfastening hold down member(s) 1617, removing and replacing back pack1612, and refastening hold down member(s) 1617. Battery pack 1612 maycomprise a battery pack such as the battery pack 1100 (FIG. 11).Further, battery pack 1612 may comprise any suitable battery pack suchas a NiCad universal battery pack of 12, 14.4 or 18 volts. In thisexample however, the battery pack 1612 is permanently mounted within ahousing 1616 mounted in a frame of generator system 1610, such as frame1402 (FIG. 14). The housing 1616 may define similar components asdescribed with respect to the enclosure 1406 (FIG. 14), but in thisexample, the housing 1616 surrounds the battery pack 1612. The housing1616 may include any suitable containment structure. It is contemplatedthat the housing 1616 may provide a removable portion, such as a door orcover plate 1620 to gain access to the battery pack 1612 in the eventthe battery pack 1612 needs to be replaced. In one example, the coverplate 1620 may be removably secured to the housing 1616, such as byfasteners (not shown).

According to an additional feature of the generator system 1610 shown inFIG. 17, a charging circuit 1630 may be provided. The charging circuit1630 may be electrically connected to the power generating device 16whereby the power generating device may provide the charging circuitwith power to charge the battery pack 1612. It should be appreciatedthat while the charging circuit 1630 is specifically illustrated for usewith the generator system 1610, it may easily be adapted for use in anyof the generator systems disclosed herein. Charging circuit 1630 wouldillustratively be switched off during starting internal combustionengine 10 of generator system 1610 and then switched on after internalcombustion engine 10 is started.

The generator system 1610 utilizes battery pack 1612 to start the ICengine 14 that turns the power generating device 16. The generatorsystem 1610 may additionally include a starting device 18 connected tothe battery pack 1612 and the starter switch. The starting device 18 maycomprise any suitable starting device such as a starter motor and tartersolenoid (see e.g., FIG. 2). The starter switch 20 may be connected tothe transistorized ignition unit 24, which is in turn connected to a thespark plug 26. The staring device 18 may be used to turn the IC engine14 at a rate sufficient to start the IC engine 14. Once the IC engine 14is started, the IC engine 14 drives power generating device 16. Thepower generating device 16 may output AC power usable by a loadconnected to the electrical outlet. Concurrently, the power generatingdevice may provide power to the charging unit 1630 to charge the batterypack 1612. The power generator device may alternatively comprise agenerator alternator (FIG. 2).

With reference now to FIG. 18, a simplified block diagram of a portablegenerator system 1800, according to additional features is shown. Theportable generator system 1800 includes an actuator switch 1802. Theactuator switch 1802 is switchable to provide electrical connectionbetween the universal battery pack 12 and the starting device 18 orbetween universal battery pack 12 and the charging circuit 1630. In thisexample, a user may place the universal battery pack 12 into the batteryreceptacle (such as battery receptacle 912, FIG. 9) and switch theactuator switch to a ‘Start’ position, thereby electrically coupling theuniversal battery pack 12 to the starting device 18. Once the actuatorswitch is in the ‘Start’ position, the starter switch 20 may also beplaced into the ‘Start’ position such that the universal battery pack 12provides power to the starting device 18 (such as a starter solenoid 34,FIG. 2). While the universal battery pack 12 has been shown, it isappreciated that alternatively, the permanently mounted battery pack1612 in housing 1616 (FIG. 17) may be used.

Once the IC engine 14 is started, the spring loaded starter switch 20may return to the ‘ON’ position. In the ‘ON’ position, the starterswitch may direct power from the ignition unit 24 to the spark plug 26.Each time spark plug 26 fires, spark is provided to IC engine 14, whichis utilized to ignite a compressed fuel and air mixture present in acylinder (not shown) during a compression cycle of IC engine 14. When ICengine 14 is running it turns alternator 36, which creates an outputvoltage usable to provide AC power at outlet 22.

In addition, once the IC engine 14 has been started, the actuator switch1662 may be moved to a ‘Charge’ position. In the ‘Charge’ position, theactuator switch 1662 may electrically connect the charging circuit 1630to universal battery pack 12 to charge the universal battery pack 12. Itis contemplated that the actuator switch 1662 may be spring-loaded sothat it returns to the ‘Charge’ position upon successfully starting theIC engine 14. It is also contemplated that the operation of the actuatorswitch 1662 and the starter switch 20 may be combined into a singleswitch. In this way, a single start switch of the generator system 1660may be wired such that charging is deactivated when the start switch isturned to the ‘Start’ position and then reactivates charging when themomentary start switch is released.

With reference now to FIGS. 19 and 20, a portable generator 1700 havingan enclosure 1706 is shown. The portable generator 1700 may include theframe 1402 that supports the IC engine 1404. The frame 1402 mayillustratively support wheels 1401 (FIG. 8), and include handles 1403for facilitating moving the generator 1700.

An electric generator device (hidden from view in FIG. 14) may becoupled to an output shaft of internal combustion engine 1404. Theelectric generator device generates AC power, such as has been describedabove. The AC power may illustratively be 120 VAC (or 110 or 115 VAC)and may also illustratively be 240 VAC (or 220 or 230 VAC). It may be 60Hz, or may be 50 Hz. Generator 1700 may also include a control panelincluding AC outlets (not shown in FIG. 14).

Generator 1700 further includes enclosure 1706 mounted to frame 1402.The enclosure 1706, which may illustratively be a water resistantenclosure, includes a rectangular tub shaped base portion 1408 andhinged lid 1710 including biasing members 1712. As will be described,the biasing member 1712 urge the batteries 1100 into the respectivebattery receptacle 1412 and charger 1414 when the hinged lid 1710 is ina closed position. The biasing member 1712 may comprise any biasingstructure such as a leaf spring for example. A pair of latches 1720 maybe provided on the hinged lid 1710 for securably coupling to a pair ofhooks 1722 provided on the base portion 1408 when hinged lid 1710 is inthe closed position.

The base portion 1408 of enclosure 1406 includes battery receptacle1412, charger 1414 and AC outlet 1416. Battery receptacle 1412 isconfigured to receive a battery pack from a cordless power tool, such asbattery pack 1100. In this regard, battery receptacle 1412 may beconfigured to receive a tower type of battery pack, such as battery pack1100, as is charger 1414. As such, battery receptacle 1412 mayillustratively have a configuration similar to battery receptacle 912described above. Battery receptacle 1412 may alternatively be configuredto receive a rail type of battery pack, such as battery pack 16 shown inU.S. Pat. No. 6,653,815, the disclosure of which is incorporated hereinin its entirety by reference. As such, battery receptacle 1412 has aconfiguration similar to that on the foot of tool 10 of U.S. Pat. No.6,653,815. That is, battery receptacle 1412 includes a pair of groovesthat receives guide rails of the rail type battery pack. It alsoincludes a connector configured to mate with the terminal block of therail type battery pack.

With specific reference now to FIG. 20, the hinged lid 1710 is shown inthe closed position. As illustrated, the biasing members 1712 engage anupper surface of the battery packs 1100 and urge them downward into thereceptacles 1412 and charger 1414. As a result, electrical connection ofbattery packs 1100 in receptacle 1412 and charger 1414 may be maintainedduring movement of the generator system 1700 such as by physicalmovement of the generator system 1700 as a whole or by vibratorymovement communicated by the IC engine 14 during use. It is appreciatedthat the biasing members 1712 may additionally be provided on thehousing 1616 disclosed for use with the permanent battery pack 1612(FIG. 17).

Turning now to FIGS. 21 and 22, a pair of adapters 1750 and 1752according to additional features of the present teachings areillustrated. The adapters 1750 and 1752 each have insertion portions1760 and 1762, respectively for receipt into battery receptacles 912(FIGS. 8-10) and/or 1412 (FIGS. 14, 19 and 20). The adapter 1750 has abattery receptacle portion 1770 while the adapter 1752 has a batteryreceptacle portion 1772. Terminals 1776 may be located in the batteryreceptacle portion 1772 for electrical communication with a battery pack(not shown) received into the adapter 1752 in the battery receptacleportion 1772. As will be described, the adapters may be selectivelyinserted into any of the battery receptacles 912, and/or 1412 enablingbattery receptacles 912 and or 1412 to accept battery packs havingdifferent footprints. In one aspect, these battery packs may be batterypacks for use with power tools such as for different brands of powertools. Footprint as used with respect to a battery back relates to abattery receptacle portion 1772 of adapter 1752 means that part of thebattery pack that is received in the battery receptacle portion 1772.

As can be appreciated, the respective battery receptacle portions 1770and 1772 may define complementary geometry to accept battery packshaving a footprint distinct from the tower 1104 of the DEWALT batterypack 1100 described in the examples above (FIG. 11). During use, adesired adapter 1750 or 1752 may be selectively inserted into batteryreceptacle 912, and/or 1412. One skilled in the art will appreciate thatthe insertion portions 1760 and 1762 mate with the receptacles 912and/or 1412 similar to a battery pack 1100. Once the desired adapter hasbeen inserted, a battery pack (not shown) having complementary matingstructure with the battery receptacle portions 1770 or 1772 may beselectively inserted into the adapter 1750, 1752.

In one example, the additional height realized by using the adapter1750, 1752 may be accommodated by the biasing member 1712. In anotherexample, other biasing members and/or hinged lids 1710 may be providedto accommodate various geometry battery packs.

FIG. 23 shows a compressor 2300 in accordance with an aspect of theinvention. The compressor 2300 may incorporate any of the featuresdiscussed herein with respect to the portable generators 800 and/or1400. The compressor 2300 includes a frame 2302 that supports aninternal combustion engine 2304, an output device such as air compressor2306 driven by the internal combustion engine 2304, and an air tank 2305coupled to an output of the air compressor 2306. A battery receptacle2312 may be electrically coupled to an electrically powered startingdevice for starting the internal combustion engine 2304 and/or chargingthe battery, such as the starting devices and charging circuitsdescribed above. In this way, the power generating device 16 may bereplaced with an output device such as the air compressor 2306, or otherassociated output of the compressor 2300.

FIG. 24 shows a power washer 2400 in accordance with an aspect of theinvention. The power washer 2400 may incorporate any of the featuresdiscussed herein with respect to the portable generator 800 and/or 1400.The power washer 2400 includes a frame 2402 that supports an internalcombustion engine 2404 and an output device such as a pump 2406 drivenby the internal combustion engine 2404. An output of pump 2406 iscoupled to a movable spray wand 2405. A battery receptacle 2412 may beelectrically coupled to an electrically powered starting device forstarting the internal combustion engine 2404 and/or charging thebattery, such as the starting devices and charging circuits describedabove. In this way, the power generating device 16 may be replaced withan output device such as a pressure regulating device, spray wand 2405,or other associated output of the power washer 2400.

It is appreciated that other power driven apparatus may be adapted foruse with the means for starting the internal combustion engine asdisclosed herein.

With reference to FIG. 25, an embodiment of control panel 806 inaccordance with some embodiments of the present invention isillustrated. Control panel 806 includes top plate 2500 and housing 2502.

An exemplary embodiment of control panel 806 is illustrated in FIG. 26.Housing 2502 has a depth sufficient to receive a battery pack, such asbattery pack 1100, in battery receptacle 912. Housing 2502 provides anenclosure for charger assembly 2510, battery receptacle 912 and theirassociated connections (not shown in figures). Top panel 2500 andhousing 2502 may be made of any suitable rigid material, e.g., stainlesssteel. Control panel housing 2502 further includes a plurality offastener holes 2504 for mounting the control panel 806 to frame 802 ofportable generator 800, as illustrated in FIG. 8. Additional fastenerholes 2504 may be utilized to secure top panel 2500 to housing 2502.

Referring now to FIGS. 27 and 28, an exemplary embodiment of chargerassembly 2510 is illustrated. Charger assembly 2510 is formed of base2520 and cage 2530. Charger assembly base 2520 includes a wire collar2522 and heat sink 2526 with associated plurality of fingers 2528. Base2520 and cage 2530 are secured together with a plurality of fasteners2515. Fasteners 2515 are inserted through fastener openings 2532 in cage2530 and received in fastener receptacles 2524 of base 2520. Fasteners2515 may comprise, for example, rivets, screws or other similarfastening devices. The use of fasteners 2515 fixedly secures the base2520 with the cage 2530 of charger assembly 2510. A charger andassociated charging circuitry (not shown) is received within chargerassembly 2510, that is, substantially enclosed between base 2520 andcage 2530. Heat sink 2526 and plurality of fingers 2528 help secure thecharger within charger assembly 2510, as well as provide protection tothe charger itself. The cage 2530 of charger assembly 2510 may include aplurality of ribs 2536 arranged to define a plurality of cage ventopenings 2534 to provide ventilation to the charger and its associatedcircuitry. Wire collar 2522 of base 2520 provides an opening for thewire of the charger to exit the charger assembly 2510. Furthermore, wirecollar 2522 reduces the strain on the wire of the charger. The wire ofthe charger may be directly coupled to the output of the powergenerating device 16 or, alternatively, may exit the housing 2502 andend in a plug that can be inserted into AC outlets 902.

Illustratively, charger assembly 2510 is assembled as a complete unitand is then installed in control panel 806. This allows, by way ofexample and not of limitation, charger assembly 2510 to be a productsupplied to the assembler of control panel 806.

Referring again to FIG. 26, charger assembly 2510 installed in housing2502 of control panel 806 is illustrated. Battery receptacle 912 iselectrically connected to the charger and its associated circuitrywithin charger assembly 2510. As described above, for example asillustrated in FIGS. 17 and 18, the electrical connections betweenbattery pack 1100 and charging circuit 1630 may include an actuatorswitch 1802. The charger of charger assembly 2510 may comprise a standalone charger (not shown) and/or charging circuit 1630, as illustratedin FIGS. 17 and 18. Furthermore, battery pack 1100 as shown in controlpanel assembly 2500 may be replaced with permanent battery pack 1612, asillustrated in FIG. 17.

Upon coupling top panel 2500 with control panel housing 2502, thesensitive circuitry and electrical connections of battery receptacle 912and charger assembly 2510 are substantially enclosed. The control panel806 provides protection to the charger and/or charging circuit 1630 and,in the case of permanently installed battery pack 1612, the battery packfrom manipulation by the user, as well as moisture, dirt and otherenvironmental conditions.

In various aspects of the present teachings, an indicating mechanism canbe connected at one or more suitable locations on the battery pack 1100,so as to be detected by the battery receptacle 912 to indicate apredetermined battery chemistry associated with the cells in the batterypack 1100. In one example, the battery receptacle 912 can detect theindicating mechanism so as to determine the chemistry of the batterypack 1100 based on the detection. In this example, detection of theindicating mechanism can indicate the predetermined battery chemistry,e.g., a lithium ion (“Li-Ion”) battery chemistry. The inability todetect the indicating mechanism, in contrast, can indicate a differentpredetermined battery chemistry, e.g., a nickel cadmium (“Ni-Cad”)battery chemistry. It will be appreciated in light of the disclosurethat detection of the indicating mechanism can be employed to detect(discern, etc.) between two battery chemistries, which can be selectedfrom a group including, without limitation, nickel cadmium, nickel metalhydride, lithium ion, zinc-carbon, zinc-chloride, alkaline(zinc-manganese dioxide, lithium (lithium-copper oxide, lithium-irondisulfide and/or lithium-manganese dioxide), mercury oxide, zinc-air,silver oxide, etc. In an aspect, the indicating mechanism may be theindicating mechanism disclosed in International Patent Application No.PCT/US2008/007271 filed Jun. 11, 2008, the entire disclosure of which isincorporated herein by reference.

The battery receptacle 912 can also detect a data signal from a dataconnection (not shown) in the terminal block 1112 to further confirm thebattery chemistry of the battery pack 1110. Specifically, detection ofboth the indicating mechanism and the data signal from the dataconnection can indicate the predetermined battery chemistry, e.g., alithium ion (“Li-Ion”) battery chemistry. The inability to detect eitherthe indicating mechanism or the data signal from the data connection, incontrast, can indicate a different predetermined battery chemistry,e.g., a nickel cadmium (“Ni-Cad”) battery chemistry.

In various embodiments, the indicating mechanism can be located in theterminal block 1112 and can be configured to be similar to the powerterminals 1114, 1116 and/or the data connection. In one example, theindicating mechanism can be referred to as a fourth terminal. By way ofthe above example, the power terminals 1114, 1116 comprise the first andsecond terminals, and the data connection can comprise a third terminal,so that the indicating mechanism can be the fourth terminal.

In other examples, the terminal block 1112 can contain a fourth terminalused for purposes other than that described above, such that theindicating mechanism can be located at other locations on the batterypack 1110 and, in various instances, outside of the terminal block 1112.As such, the indicating mechanism can be referred to as a fifthterminal, or whatever terminal, connection, etc. may be applicable basedon the configuration of the battery pack 1110. It will be appreciatedthat the indicating mechanism can be located at various locations on thebattery packs regardless of whether the battery pack 1110 is providedwith a rail configuration or the tower configuration illustrated in FIG.11.

With reference to FIG. 29, one example of an indicating mechanism 1150is shown associated with a battery pack 1152 and a battery receptacle1154. The indicating mechanism 1150 can be configured so as to include aspring member 1156 that can extend from the battery receptacle 1154 andcontact the battery pack 1152. The spring member 1156 can contact aconnector 1158 on the battery pack 1152 so that, for example, areference voltage can be detected by the battery receptacle 1154 and/orthe battery pack 1152. Detecting the indicating mechanism 1150,therefore, can include detecting the reference voltage.

In a further example, the spring member 1156 can contact the connector1158 on the battery pack 1152 so that, for example, continuity can bedetected by the battery receptacle 1154 and the battery pack 1152. Inthis case, detecting the indicating mechanism 1150 can, therefore,include detecting continuity.

In other examples, the indicating mechanism 1150 can include a springmember 1156 that can extend from the battery receptacle 1154 and contactthe battery pack 1152. In this example, the spring member 1156 cancontact a portion of the battery pack 1152 so that, for example,deflection of the spring member 1156 can activate a switch (e.g., amicro switch) and/or one or more suitable mechanical orelectromechanical devices. Detecting the indicating mechanism 1150 can,therefore, include detecting a signal from the switch activated by theindicating mechanism 1150.

With reference to FIG. 30, an example of an indicating mechanism 1160 isshown associated with a battery pack 1162 and a battery receptacle 1164.The indicating mechanism 1160 can include a spring member 1166 that canextend from the battery pack 1162 and contact the battery receptacle1164. Similar to the indicating mechanism 1150 in FIG. 29, the springmember 1166 can contact a connector 1168 on the battery receptacle 1164so that, for example, a reference voltage or continuity can be detected.In addition, the spring member 1166 can activate a switch as explainedabove.

With reference to FIG. 31, one example of an indicating mechanism 1170is shown associated with a battery pack 1172 and a battery receptacle1174. The indicating mechanism 1170 can include an emitter 1176 and areceiver 1178. In general, detecting the indicating mechanism 1170 can,therefore, include detection of one or more electromagnetic wave signals1180 from the emitter 1176 by the receiver 1178. In one instance, theemitter 1176 can be one or more members that can produce a magneticfield (e.g., a magnet, an electromagnet, etc.). The receiver 1178 can bea hall-effect sensor. Detection of the indicating mechanism 1170 can,therefore, include the hall-effect sensor detecting the one or moremembers that produce the magnetic field. In a further example, theemitter 1176 can emit a radio frequency (RF) signal that can be received(i.e., detected) by the receiver 1178. In this instance, detection ofthe indicating mechanism 1170 can, therefore, include the receiver 1178detecting the RF signal from the emitter 1176. It will be appreciated inlight of the disclosure that the emitter 1176 can be located in or onthe battery pack 1172 and the receiver 1178 can be located in or on thebattery receptacle 1174 or vice versa, as applicable.

With reference to FIGS. 32 through 39, various positions of anindicating mechanism can be shown on a battery pack having a towerconfiguration. It will be appreciated in light of the disclosure thatsimilar locations, as applicable, can be implemented on a battery packhaving a rail configuration such as those configured to be used withadaptor 1750 illustrated in FIG. 21. With reference to FIG. 32, abattery pack 2200 can include an indicating mechanism 2202. Theindicating mechanism 2202 can be in a position that is relatively closeto a terminal block 2204 that can contain a data connection and/or acommunication connection (not shown). In this example, the indicatingmechanism 2202 can be located on a tower portion 2206 outside of theterminal block 2204.

With reference to FIG. 33, a battery pack 2220 can include an indicatingmechanism 2222 that can be located on an upper deck 2224 of a bodyportion 2226 of the battery pack 2220. It will be appreciated in lightof the disclosure that the positioning of the indicating mechanism 2222,in the example illustrated in FIG. 33, can be at a greater distance froma terminal block 2228 than the indicating mechanism 2202 relative to theterminal block 2204, as illustrated in FIG. 32.

It will be appreciated in light of the disclosure that other examples ofplacement of the indicating mechanism on the battery pack, examples ofwhich are illustrated throughout FIGS. 32-39, can include locations ofthe indicating mechanism that can maximize a distance between a terminalblock and the indicating mechanism. The distance between the terminalblock and the indicating mechanism can be maximized for various reasons.One reason can be shown to include avoiding obstructing the powerconnection, the data connection and the indicating mechanisms with, forexample, a paint spill or other debris from the work site. By maximizingthe distance between the data connection (and/or the power connection)and the indicating mechanism, it can be shown that the propensitysomehow obstruct, cover, deactivate, etc. both the data connection andthe indicating mechanism so as to not detect the data connection and/orthe indicating mechanism as a proxy for a predetermined batterychemistry can be reduced.

With reference to FIG. 34, a battery pack 2240 can include an indicatingmechanism 2242 that can be positioned on a lower deck 2244 of thebattery pack 2240. FIG. 35 illustrates an example of an indicatingmechanism 2250 being on a side area 2252 of a battery pack 2254. Whilethe indicating mechanism 2250 is illustrated on the side area 2252 of abase portion 2256, it will be appreciated in light of the disclosurethat the indicating mechanism 2250 can be on a side of a tower portion2258 in lieu of the base portion 2256.

With reference to FIG. 36, a battery pack 2260 can include an indicatingmechanism 2262 being on a side area 2264 of the battery pack 2260. Whilethe indicating mechanism 2262 is illustrated on the side area 2264 of atower portion 2266, it will be appreciated in light of the disclosurethat the indicating mechanism 2262 can be on the side area 2264 of abase portion 2268 in lieu of the tower portion 2266. Moreover, the sidearea 2264 of the tower portion 2266 on which the indicating mechanism2262 is located can be opposite the surface relative to the location ofthe indicating mechanism 2202 on the battery pack 2200, as illustratedin FIG. 32.

With reference to FIG. 37, a battery pack 2270 can include an indicatingmechanism 2272 that can be located on a front area 2274 of the batterypack 2270. While the indicating mechanism 2272 is illustrated on thefront area 2274 of a base portion 2276, it will be appreciated that theindicating mechanism 2272 can be on the front area 2274 of a towerportion 2278 in lieu of the base portion 2276. In FIG. 38, a batterypack 2280 can include an indicating mechanism 2282 being on a rear area2284 of the battery pack 2280. While the indicating mechanism 2282 isillustrated on the rear area 2284 of a tower portion 2286, it will beappreciated that the indicating mechanism 2282 can be on a rear area2284 of a base portion 2288, in lieu of the tower portion 2286.

With reference to FIG. 39, a battery pack 2290 can include an indicatingmechanism 2292 that can be located on a side area 2294 of the batterypack 2290 having an enlarged tower portion 2296 The enlarged towerportion 2296 can sometimes be referred to as a two-up or a two towerconfiguration. While the indicating mechanism 2292 is illustrated on theside area 2294 of one tower portion 2296, it will be appreciated inlight of the disclosure that the indicating mechanism 2292 can be onvarious areas of the battery pack 2290 including, but not limited to,the locations provided in the above examples.

Referring now to FIGS. 40-43, a housing 3915 for use in conjunction withbattery receptacle 912 (FIG. 9) according to various embodiments of thepresent disclosure is illustrated. Housing 3915 comprises two housinghalves 3914 and terminal slot part 3920. Similar to the housing 915illustrated in FIGS. 12 and 13, housing 3915 is adapted to mate with abattery pack of a tower configuration, such as battery pack 1100illustrated in FIG. 11. Housing halves 3914 are adapted to mate togetherwith terminal slot part 3920 to form housing 3915, as shown in FIG. 40.Housing 3915 is affixed to mounting plate 3916 (FIG. 43) which mounts tocontrol panel 806.

Terminal slot part 3920, as best seen in FIG. 42, is adapted to matewith terminal block 1112 of battery pack 1100. Thus, terminal slot part3920 has a complementary shape to terminal block 1112. Terminal slotpart 3920 includes a base portion 3921 and a recess 3928. Situatedwithin the recess 3928, terminal protrusion 3924 and keying features3922 may extend to be substantially coplanar with base portion 3921. Thekeying features 3922 are designed to mate with complementary recesses inthe battery pack 1100. Keying features 3922 provide numerous functions,including assisting with the proper insertion of the battery pack withinhousing 3915 and locking out incompatible batteries or compatiblebatteries that are inserted incorrectly (e.g., backwards). Furthermore,keying features 3922 may provide functionality similar to that of theindicating mechanism described above. For example, keying features 3922could interact with switches or terminals in the inserted battery packto indicate the battery chemistry of the inserted battery pack, asdescribed above.

Terminal protrusion 3924 provides the additional functionality ofguiding the battery pack into proper mating position with terminal slotpart 3920. Terminal protrusion 3924 also protects the chargingterminals, such as power terminals 1114, 1116 and temperature senseterminal 1118 illustrated in FIG. 12, from being touched or contacted bya user of the generator. The terminals are received in terminal slots3925, which may also include keying features 3926. Keying features 3926may act in conjunction with, or independently of, the keying features3922 present in the recess 3928 of terminal slot part 3920. In theillustrative embodiment shown in FIG. 42, the opposed terminal slots3925 include the keying features 3926. When a battery pack 1100 isinserted into housing 3915, the battery terminals 1114, 1116, 1118extend through terminal slots 3925 and contact charging terminals, suchas terminals 1204, 1206 illustrated in FIG. 12.

With reference to FIG. 41, a magnetic sensor 4100, such as a Hall effectsensor, is received in housing 3915. When battery pack 912 is a Li-Ionbattery pack, a magnet in battery pack 912 will align with magneticsensor 4100 when battery pack 912 is received in housing 3915.

With reference to FIG. 43, a terminal board 4302 is affixed to a bottom4300 of housing 3915. With reference to FIG. 44, terminal board 4302includes terminals that extend into terminal slots 3925 includingpositive terminal 4400, negative terminal 4402, and third terminal 4404.A negative temperature coefficient sensor 4406 is affixed to negativeterminal 4402. Illustratively, when battery pack 912 is a NiCad batterypack, third terminal 4404 connects to a temperature sensor in the NiCadbattery pack. Illustratively, when battery pack 912 is a Li-Ion batterypack, third terminal 4404 provides a data terminal and in conjunctionwith magnetic sensor 4100, is used to verify that the battery pack 912is a Li-Ion battery pack.

Referring now to FIGS. 45 and 46, housing half 3914 is illustrated withpartially inserted exemplary battery pack 4500. Battery pack 4500includes terminals 4502 and keying features 4504 for mating withterminal slot part 3920. As described above, the terminal slot part 3920includes terminal protrusion 3924 and keying features 3922 that matewith the terminals 4502 and keying features 4504 of battery pack 4500when the battery pack is received within the housing. FIG. 46 shows abattery receptacle housing half 3914 with battery pack 4500 completelyinserted within housing half 3914 and terminal slot part 3920. Thebattery pack 4500 is inserted within terminal slot part 3920 such thatthe terminals 4502 mate with a terminal board 4302.

Referring now to FIG. 47, a magnetic sensor 4100, such as a Hall effectsensor, may be present in the housing 3915. Magnetic sensor 4100 willdetect the presence of a magnet 4510 in the battery pack 4500 when it isinserted into the housing 3915. The magnetic sensor 4100 is coupled tothe electronics of the portable generator through wires 4102 in theillustrated examples, however, other means of communication (e.g.,wireless communication) may be employed. Wires 4102 may be integratedwithin the housing 3915 or otherwise anchored in fixed relation tohousing 3915.

Those skilled in the art can now appreciate from the foregoingdescription that the broad teachings of the present invention can beimplemented in a variety of forms. Therefore, while this invention hasbeen described in connection with particular examples thereof, the truescope of the invention should not be so limited since othermodifications will become apparent to the skilled practitioner upon astudy of the drawings, specification and following claims.

1. A portable electrical generator system, comprising: a manuallymovable frame supporting an internal combustion engine that drives agenerator device supported on the frame that generates AC power, theinternal combustion engine coupled to the generator device; a startingdevice coupled to the internal combustion engine; and a control panelassembly coupled to the frame, comprising: a control panel having atleast one AC outlet coupled to the generator device; a housing having abattery receptacle therein electrically coupled to the starting device,the battery receptacle configured to receive a cordless power toolbattery pack, the battery pack received in the battery receptacle andproviding electrical power to the starting device; a charger assemblyincluding a charger electrically coupled between the battery packreceived in the receptacle and the generator device when the internalcombustion engine is running to charge the battery pack and electricallydecoupled from the battery pack when the internal combustion engine isbeing started; and the charger assembly including a base portion coupledto a cage portion, the charger received on the base portion.
 2. Thesystem of claim 1, wherein the charger is substantially enclosed by thebase portion and the cage portion.
 3. The system of claim 2, wherein thecage portion comprises a plurality of ribs arranged to define vents inthe cage portion.
 4. The system of claim 1, wherein the charger assemblyis coupled to the housing of the control panel assembly.
 5. The systemof claim 1, wherein the charger assembly further comprises a wire collaradapted to support a wire connection from the charger.
 6. The system ofclaim 5, wherein the wire connection comprises a wire extending from thecharger, passing through the wire collar and terminating with a plug. 7.The system of claim 6, wherein the plug is insertable into the at leastone AC outlet.
 8. The system of claim 7, wherein the battery pack ischarged when the internal combustion engine is running and the plug isinserted into the at least one AC outlet.
 9. The system of claim 5,wherein the wire connection extends though the housing.
 10. The systemof claim 1, wherein the charger comprises a stand alone charger that issubstantially enclosed within the base and cage portions.
 11. The systemof claim 10, wherein the stand alone charger comprises a wire extendingfrom the base and cage portions and terminating with a plug.
 12. Thesystem of claim 11, wherein the plug is insertable into the at least oneAC outlet.
 13. The system of claim 12, wherein the battery pack ischarged when the internal combustion engine is running and the plug isinserted into the at least one AC outlet.
 14. The system of claim 13,wherein the wire extends though the housing. The system of claim 1,wherein the battery receptacle receives a battery pack that is one of aplurality of battery packs having different voltages, the systemincluding a voltage regulation circuit coupling the battery receptacleto the starting device, the voltage regulation circuit providing at anoutput coupled to the starting device a voltage at a desired level forthe starting device regardless of the voltage of the battery packreceived in the battery receptacle.
 15. A portable electrical generatorsystem, comprising: a manually movable frame supporting an internalcombustion engine that drives a generator device supported on the framethat generates AC power, the internal combustion engine coupled to thegenerator device; a starting device coupled to the internal combustionengine; and a control panel assembly coupled to the frame, comprising: acontrol panel having at least one AC outlet coupled to the generatordevice; a housing having a battery receptacle therein electricallycoupled to the starting device, the battery receptacle adapted toreceive a cordless power tool battery pack for providing electricalpower to the starting device when the battery pack is received in thebattery receptacle; and a charger assembly substantially enclosed withinthe control panel and the housing, comprising: a stand alone chargerelectrically coupled between the battery pack received in the receptacleand the generator device when the internal combustion engine is runningto charge the battery pack and electrically decoupled from the batterypack when the internal combustion engine is being started; and a baseportion coupled to a cage portion, the stand alone charger received onthe base portion and substantially enclosed by the base portion and cageportion.
 17. The system of claim 15, wherein the battery receptaclecomprises a keying feature configured to mate with a complementary keyof the cordless tool battery pack when the cordless tool battery pack isproperly inserted in the battery receptacle.
 17. The system of claim 16,wherein the keying feature is configured to inhibit insertion of thecordless tool battery pack when incorrectly inserted in the batteryreceptacle.
 18. The system of claim 16, wherein the keying feature isconfigured to indicate a battery chemistry of the cordless tool batterypack when inserted in the battery receptacle.
 19. The system of claim16, wherein the battery receptacle is configured to determine a batterychemistry of the cordless tool battery pack by sensing an indicatormechanism on the cordless tool battery pack.
 20. The system of claim 15,wherein the battery receptacle is configured to determine a batterychemistry of the cordless tool battery pack by sensing an indicatormechanism on the cordless tool battery pack.
 21. The system of claim 15,wherein the stand alone charger is plugged into the at least one ACoutlet.
 22. The system of claim 15, wherein the stand alone charger iselectrically coupled to the generator device by hard wiring.